Laminating equipment for laminating multilayer endless webs for the manufacture of energy cells.

Abstract

The present invention relates to a laminating apparatus for a multilayer endless web 3 for the manufacture of an energy cell, comprising at least one separator web 4, 6 and at least one electrode, wherein the laminating apparatus has a press device, which laminates the multilayer endless web 3 through a press surface under the action of pressing force, and the press surface has different parts having different spring stiffnesses.

Description

Technical Field

[0001] The present invention relates to a laminating device for laminating a multilayer endless web for the production of energy cells, having the features of the superordinate concept of claim 1.

Background Art

[0002] An energy cell or, equally, an energy storage unit in the sense of the present invention is for example, in automobiles, other land vehicles, ships, airplanes, or equally, used in installed equipment such as, for example, a photovoltaic power generation facility, in the form of a battery cell or a fuel cell, in which a very large amount of energy needs to be stored over a relatively long time interval.

[0003] For this purpose, it is possible for such an energy cell to have a structure consisting of a plurality of segments laminated into one laminate. These segments are each formed from alternating anode sheets and cathode sheets, which are separated from each other by separator sheets, which are likewise manufactured as segments. The segments are pre-cut within the manufacturing process and then stacked into the laminate in a predefined order and joined to each other by lamination. In that case, the anode sheets and the cathode sheets are first cut from an endless web and then placed onto an endless web of separator material in an individualized state with a spacing. This subsequently formed "two-layered" endless web consisting of separator material with the placed anode sheet or cathode sheet is then, in a first step, again cut into segments with a cutting device, where these segments are, in this case, formed in a two-layered manner by separator sheets with the anode sheet or cathode sheet placed thereon. To the extent that this is technically feasible or necessary, endless webs of separator material having anode and cathode sheets can be stacked prior to cutting, thereby forming an endless web having a first endless layer of separator material having an anode or cathode sheet placed on top of it, and a second endless layer of separator material also having an anode or cathode sheet placed on top of it. This "four-layered" endless web is then cut into segments using a cutting device, and these segments are formed in this case in four layers: a first separator sheet, an anode sheet, a second separator sheet, and a cathode sheet adjacent to the second separator sheet. The advantage of this solution is that one cut may be saved. Furthermore, the cut electrodes may similarly be placed on an endless separator web and stacked on yet another endless separator web to form a three-layer endless web, from which a three-layer segment having a separator sheet, an electrode sheet, and yet another separator sheet is then cut. In the spirit of this invention, a segment is accordingly a single-layer segment of a separator material, an anode sheet, or a cathode sheet, or similarly, a two-layer, three-layer, or four-layer segment of the above-described structure.

[0004] Furthermore, the aforementioned "two-layer" or "four-layer" endless webs can similarly be complemented into "three-layer" or "five-layer" endless webs by placing yet another separator sheet on top of the electrodes, in which case these endless webs each have a separator web on both sides.

[0005] Selectively, electrodes can exist in an endless web, i.e., uncut, in a "two-layer," "three-layer," "four-layer," or "five-layer" endless web, which are then cut into significantly longer lengths and then, for example, wound up. Selectively, the endless web can be first wound up and then cut after the winding is complete. In this case, the electrodes do not exist as spaced segments within the endless web, but rather, instead, they exist within a single segment, which extends uninterrupted within the intermediate space between the separator webs.

[0006] Furthermore, within the endless web, electrodes in the form of a copper web, copper film, or comparable support material may be provided with intermittent coverings. In this electrode, each of these covering portions forms a section-like, spaced-out rising portion within the electrode.

[0007] For laminating "two-layer," "three-layer," "four-layer," or "five-layer" endless webs, these endless webs are guided between two press devices, which apply a pressing force to the endless webs. In this case, electrodes are pressurized together with the separator web within the endless web. Essentially, the electrodes, along with the separator web, are bonded and laminated together by the action of pressing force using a press device. Additionally, lamination can be assisted by the heat generated by the pressing force. Furthermore, additional heating zones or cooling zones may be provided to regulate the temperature of the endless web during lamination. For the realization of high-quality bonding, it is desirable that the endless web be subjected to the same compressive force as much as possible along its longitudinal and transverse extensions.

[0008] As long as the electrodes are spaced apart from each other in the form of already cut segments within the endless web, These electrodes, based on their spacing, additionally form intermediate spaces within the endless web, and in doing so, these electrodes additionally hold the separator webs at a certain distance from each other, based on the thickness of these separator webs within the intermediate spaces. Consequently, the electrodes have additional free edges on the side surfaces of the edges that demarcate the intermediate space. Furthermore, the endless web has additional thickness variations as a result.

[0009] In that case, the endless web to be laminated has a variable thickness, which is determined solely by the unavoidable manufacturing imperfections between the electrodes and the separator web, and / or the spacing between the electrodes, in the thickness between the electrodes and the separator web. Furthermore, the electrodes are formed thinner than the separator web, and therefore, additionally, different thicknesses of the endless web are given within the edge region of the endless web based on the arrangement of the electrodes within the endless web.

[0010] This thickness variation of the endless web induces dynamic stresses in the press within the laminating apparatus. Furthermore, the thickness variation induces fluctuations in the pressing force acting on the endless web from the press, and increased pressure loads on the free edges, which carries a risk of edge damage. [Overview of the Initiative] [Problems that the invention aims to solve]

[0011] Given this background, the fundamental problem underlying this invention is: The objective is to provide a laminating apparatus that enables improved lamination of an endless web within the marginal zone adjacent to the electrode, with a reduced probability of electrode damage within the marginal region. [Means for solving the problem]

[0012] In accordance with the present invention, a laminating apparatus having the features of claim 1 is proposed to solve this problem.

[0013] Further advantageous developments can be seen from the dependent claims, drawings, and descriptions to which they belong. [Effects of the Invention]

[0014] In accordance with the basic concept of the present invention, it is proposed that the press surface has different parts having different spring rigidities. Due to the different spring stiffnesses, the press surface is purposefully made more rigid in predetermined areas and, consequently, transmits greater pressing force. In contrast, it is possible to form this pressing surface to transmit a smaller pressing force in areas with lower spring stiffness. In this way, in particular, the thickness differences within the endless web based on the arrangement of electrodes within the endless web can be compensated by the press surface intentionally flexing and elastically contracting in areas with lower spring stiffness than in areas with higher spring stiffness. As a result, this pressing force is also compensated for by a contour-adjusted pressing force, so that thickness variations have less influence on the pressing force, and thus lamination is carried out with a basically more constant pressing force acting on the endless web. With respect to the thickness variations of the endless web, synchronously configured pressing forces can create zones with higher and lower pressing forces in each section, and therefore, the resulting bonding force of the lamination can be purposefully influenced. Particularly in the part where the press surface has a low spring stiffness, for the purpose, in the part where it has a higher spring stiffness, by bending and elastically contracting, without increasing the dynamic load of the entire system, in order to avoid damage to the free edge, within the area having a free edge, the press force can be synchronously reduced with respect to the thickness variation and the free edge.

[0015] Furthermore, it is proposed that the pressing device laminates a multi-layer endless web in the laminating device under the introduction of heat. Lamination, that is, the joining of endless webs of separator materials and the joining with electrodes, is carried out by the polymer penetrating from one layer to the other layer, which is caused by the adhesive force acting within the interface. Exactly this adhesive force can be simply achieved by the introduction of heat. In that case, however, it must be noted that the material within the interface is not compressed to the extent that important ion exchange for the function of the energy cell is blocked under the introduction of heat and the acting pressing force.

[0016] In that case, it is possible that different spring stiffnesses are advantageously realized by the spring-elastic support of the press surface within the pressing device. In that case, it is possible that the different spring stiffnesses realized by the spring-elastic support of the press surface are realized by individual segments spring-elastically supported within the press surface, or else within the press surface supported non-spring-elastically, or are realized by a plurality of spring-elastically supported segments having different spring stiffnesses.

[0017] Furthermore, it is possible that different spring stiffnesses are realized additionally or selectively by different spring stiffnesses of the material of the press surface. This can be achieved, for example, by locally different arrangements of the reinforced material ratio within the press surface, or by locally different combinations of different materials, and / or by dimensioning the press surface at different thicknesses.

[0018] Furthermore, the electrode has a width smaller than that of the separator web in the longitudinal direction of the endless web, and it is proposed that the press surface has a higher or lower spring stiffness in the region where this press surface covers at least one protruding edge of the separator web than in the region where this press surface covers the electrode. With the proposed solution, the endless web is laminated with a higher pressing force in at least one edge region than in the region of the electrode. This induces a stronger bonding of the endless web in the edge region at a lower load of the electrode. Furthermore, instead of being configured to be higher, the spring stiffness can also be configured to be lower. Thus, the press surface intentionally deflects more strongly in the region of the protruding edges of the separator web. Since the endless web is formed "more flexibly" based on the resistance surface that would otherwise be formed by the electrode and does not exist within the region of the edges of the separator web itself, the press surface acts on these parts with a purposefully smaller pressing force.

[0019] Furthermore, it is proposed that a plurality of electrodes are provided in the endless web, regularly arranged at intervals from each other. The endless web is accordingly pre-mass-produced for the manufacture of multilayered individual segments each having one electrode or an electrode pair. For the manufacture of the segments, the endless web then only needs to be cut into individual segments by a simple cutting process. As long as the endless web is an endless web having intermittent covering portions, the covered portions correspond to electrodes, and the spacing between these covering portions corresponds to the spacing between electrodes.

[0020] Furthermore, in this case, the pressing surface is It is proposed that this press surface has higher or lower spring stiffness in the portion of the electrode spacing that contacts the endless web than in the electrode region that contacts the endless web. Due to the higher spring stiffness within the electrode spacing region, the endless web is subjected to relatively higher pressing forces within that portion of the endless web than within the electrode region. This allows the pressing surface to intentionally flex more within the electrode region than within the intermediate space or electrode spacing region, thus preventing damage to the electrodes during lamination and resulting in improved lamination of the separator web within the intermediate space region. The press surface, accordingly, has a distribution of areas with higher spring stiffness corresponding to the arrangement of the intermediate space, and a distribution of areas with lower spring stiffness corresponding to the distribution of the electrodes. Furthermore, the spring stiffness can be configured to be lower as well as higher, so that the press surface can be intentionally made to flex more strongly in the area where it contacts the endless web within the region of the electrode spacing. Since the endless web is formed "thinner" based on the resistance surface that would otherwise be formed by electrodes, which does not exist within the region of the spacing, the press surface applies intentionally smaller pressing force to these parts.

[0021] Furthermore, it is proposed that the press device comprises at least one press roll having a circular cross-section, and that the press surface is formed by the outer surface of the press roll. With the proposed formation of the press device, the laminating device can be advantageously integrated into a drum passage, which in turn enables extremely high production capacity. The outer surface of the press roll further forms a particularly advantageous pressing surface, because this outer surface can be manufactured with great precision and, by rolling along the endless web, enables continuous linear pressing of the endless web across its entire width.

[0022] In this case, at least one sheath segment is provided within the sheath surface, supported radially in a spring-elastic manner, and the radially outer surface of the sheath segment can form part of the press surface. Consequently, the pressing surface is locally elastic within the area of ​​the outer sheath segment, and therefore, the pressing force for laminating the endless web is smaller within this area. For this purpose, the sheath segments can be positioned and sized to cover the electrodes as they roll on the endless web, so that the load on these electrodes is intentionally reduced during lamination, or in other words, the endless web is laminated with a higher pressing force in the intermediate space region than in the electrode region. Furthermore, the spring-elastic sheath segments can also be positioned so that the electrodes are purposefully positioned to reduce the load on these electrodes within the ridge region.

[0023] Furthermore, the press device has at least one press belt, and The pressing surface is formed by the surface of the press belt. It is proposed that the press belt contacts the endless web under the action of a pressing force on this surface. The use of a press belt within a press machine to realize a pressed surface is The advantage is that the pressing force can be generated during lamination by an appropriate pressing force generating device and distributed to the endless web via this press belt in a distribution defined by the shaping and formation of the press belt. In that case, the press belt has the advantage that, based on the belt shape of the press belt, the force transmission surface can be extended to a greater length than the endless web.

[0024] In this case, the press belt may have different spring stiffnesses in the direction of the applied pressing force along its longitudinal extension. The press belt, as a result, has a rigid zone and a zone that is intentionally formed to be more flexible. The press belt can be adapted to the thickness differences of the endless web, so that the endless web can be subjected to less load in the zone with greater thickness. The press belt is able to flex in an improved manner within zones, for example, within zones of contact with the endless web where electrodes are located, and thus pressure peaks during lamination can be reduced.

[0025] In that case, the press roll can, advantageously, contact the free side of the press belt and press the press belt against the endless web under the action of compressive force. In this case, the press roll is a pressing force generating device having the advantages described above, and these features are combined with the advantages of using a press belt for an even more improved solution.

[0026] In a more advantageous further development, it is proposed that the press rolls and / or press belts are moved and / or driven synchronously with respect to the endless web.

[0027] The bonding force can be appropriately and purposefully influenced by the synchronous movement of the endless web relative to the press roll and / or press belt. In this way, the pressing force in a region with free edges, for example, can be reduced synchronously with respect to thickness variations and free edges.

[0028] The present invention will be described below based on advantageous embodiments and in reference to the attached figures. [Brief explanation of the drawing]

[0029] [Figure 1] This is a diagram of a part of a laminating apparatus, showing a four-layer endless web and a press device having two press rolls. [Figure 2] This is a partial diagram of a laminating apparatus, showing a three-layer endless web and a press device having two press rolls and two press belts. [Modes for carrying out the invention]

[0030] In Figure 1, a portion of a laminating apparatus according to the present invention can be recognized, and in this laminating apparatus, The endless web 3 has a separator web 4 on the upper side, a separator web 6 in the center, a plurality of anodes 5 positioned between these separator webs 4 and 6, and a plurality of cathodes 7 positioned below the central separator web 6. It is formed by a four-layered endless web 3. The anode 5 is formed to be larger than the cathode 7, and therefore, when these anodes 5 are arranged in a pair with these cathodes 7, they have a smaller end-face gap A between them than the cathodes 7. The laminating apparatus further comprises a press apparatus having two press rolls 1 and 2, which are formed as cylindrical drums having a circular cross-section. The press rolls 1 and 2 are aligned parallel to each other along their rotational axes, and are positioned such that a gap S with a constant gap width SW exists between the outer surfaces 12 and 13 of the press rolls in the direction of the rotational axis and therefore perpendicular to the illustrated plane.

[0031] The gap width SW of the gap S is set to be smaller than the thickness D of the endless web 3, so that the endless web 3 is slightly compressed and laminated as it passes through the gap S. The thickness D2 of the separator webs 4 and 6 ranges from 15 to 25 μm, while the electrode 5 has a thickness D1 ranging from 150 to 400 μm. Consequently, the thickness D of the electrode web 3 ranges from approximately 330 μm to 850 μm. The gap width SW is set to be 20 to 100 μm, preferably 40 to 60 μm, smaller than the thickness D of the endless web, so that the endless web 3 is slightly compressed when passing through gaps S of only 5 to 10 μm. The intermediate space 8 is formed by the spacing of the electrodes and has a height corresponding to the electrode thickness D1, i.e., 150 to 400 μm. Furthermore, the intermediate space 8 has a length corresponding to the spacing A between the electrodes 5, which is 3 mm between the anodes and 6 mm between the cathodes in the supply direction. In this case, it is worth pursuing to make the spacing A between these electrodes 5 as small as possible in order to increase the material utilization of the endless web 3 and to increase the number of electrodes 5 within a predetermined length of the endless web 3.

[0032] The endless web 3 is transported in the supply direction T and, in that case, pulled through the gap S. The press rolls 1 and 2 can themselves be actively driven, for example by individual drive devices in the form of servo motors, to rotate in opposite directions aligned in the direction of the arrow P, so that these press rolls actively transport the endless web 3, additionally through frictional engagement. Selectively, the press rolls 1 and 2 may be supported only rotatably, and thus these press rolls may be driven by themselves to rotate through frictional engagement with the endless web 3. In this case, the press rolls 1 and 2 simply roll passively on the surface of the endless web 3.

[0033] The outer surfaces 12 and 13 of the press rolls 1 and 2 here form the pressing surface of the press device. The outer surface 12 of the upper press roll 2 is spring-loaded by a plurality of springs F1 to F5 having different spring stiffnesses, and therefore these outer surfaces deflect differently depending on the rotational angle position of the press roll 2 and the contact state with the endless web 3 defined thereby. The same applies to the lower press roll 1 in the figure, which has springs F6 to F10, and these springs act on the outer surface 13.

[0034] In Figure 2, a selective embodiment of the present invention can be seen. The press device here comprises, alongside both press rolls 1 and 2, two additional press belts 20 and 21, which are in contact with the upper and lower surfaces of the endless web 3. The press rolls 1 and 2 are formed and positioned identically to those in Figure 1, and are in contact with the free surfaces of both press belts 20 and 21.

[0035] Furthermore, an endless web 3 to be laminated is provided, which extends through the gap S and has a thickness D. The endless web 3 is formed by a "three-layer" endless web 3 having a separator web 4 on the upper side, a separator web 6 on the lower side, and an anode 5 positioned between them. These anodes 5 are arranged at the same interval A with an intermediate space 8 between them, and have a width smaller than the separator webs 4 and 6, so that these separator webs 4 and 6 protrude laterally beyond the anodes 5.

[0036] Basically, an anode 5 larger than the cathode 7 is formed within the energy cell, and the separator webs 4 and 6 are identical, and like the anode 5, are also used for the placement of the cathode 7, which is recognizable in Figure 1. Therefore, the spacing A of the intermediate space 8 between the cathode 7 and the free lateral edge zone is particularly large in the case of these cathodes 7. In the reverse inference, the spacing A of the intermediate space 8 and the free edge side are smaller than in the case of the anode 5.

[0037] The springs F1 to F10 within press rolls 1 and 2 are sized such that the press surfaces formed by the outer surfaces 12 and 13 are purposefully rigid within defined surrounding areas and purposefully flexible within other areas, by having different spring stiffnesses. Consequently, the press surface can flex differently in the event of unavoidable thickness variations of the endless web 3, for example, based on the intermediate space 8. Accordingly, the endless web 3 can be laminated with fewer pressure peaks and with reduced load on the electrodes 5, particularly in the region of the edges adjacent to the intermediate space 8.

[0038] In the embodiment shown in Figure 2, two additional press belts 20 and 21 are provided alongside the press rolls 1 and 2. Within the press rolls 1 and 2, a plurality of springs F1 to F10 having different spring stiffnesses are provided, corresponding to the embodiment shown in Figure 1. Selectively or additionally, the press belts 20 and 21 may be formed to have different spring stiffnesses in the direction of the press force applied to the endless web 3. For this purpose, the press belts 20 and 21 may be realized, for example, as woven belts with localized fiber reinforcement, or as other combinations of different materials. Furthermore, individual sheath segments may be provided within the sheath surfaces 12 and 13 of the press rolls 1 and 2, and these sheath segments form a portion of the sheath surfaces 12 and 13 with their surfaces and are separately supported in a spring-elastic manner. Instead of press rolls 1 and 2, the use of rod carpets (Stangenteppich), piston cylinder units, and pneumatically operated pressing devices having inflatable cushions as pressing force generators can also be considered. As press belts 20 and 21, particularly fiber-reinforced woven belts, steel belts, or similarly extremely slender link belts may also be used.

[0039] In that case, the laminating apparatus may be configured such that the pressing apparatus has a distribution of spring stiffness adapted to the thickness distribution of the endless web to be laminated within the pressing surface, in which case, in particular, the dimensions of the electrodes 5 and the position of the intermediate space 8, including the spacing A between these electrodes within the intermediate space 8, are taken into consideration.

Claims

1. A laminating apparatus for a multilayer endless web (3) comprising at least one separator web (4, 6) and at least one electrode, for the manufacture of an energy cell, wherein the laminating apparatus is - It has a press device, and this press device laminates the multilayer endless web (3) through the press surface under the action of pressing force. In the laminating apparatus described above, - The press surface has different parts with different spring stiffnesses. A laminating apparatus characterized by the following features.

2. - The press device laminates the multilayer endless web (3) under the introduction of heat. The laminating apparatus according to feature 1.

3. - Different spring stiffnesses are achieved by spring-elastic support of at least one portion of the pressing surface within the pressing device. The laminating apparatus according to claim 1 or 2.

4. - Different spring stiffnesses are achieved by the different spring stiffnesses of the materials used on the press surface. A laminating apparatus according to any one of features 1 to 3.

5. - The electrodes have a narrower width than the separator webs (4, 6) in the longitudinal direction of the endless web, and, - The press surface is, In the region where this press surface covers at least one protruding edge of the separator web (4, 6), the spring stiffness is higher or lower than in the region where this press surface covers the electrode. A laminating apparatus according to any one of features 1 to 4.

6. - Within the endless web (3), multiple electrodes are provided, which are cut and regularly spaced apart from each other. A laminating apparatus according to any one of features 1 to 5.

7. - The press surface is, The pressing surface has a higher or lower spring stiffness in the portion of the electrode spacing that contacts the endless web (3) than in the electrode region that contacts the endless web (3). The laminating apparatus according to feature 6.

8. - The press device comprises at least one press roll (1, 2) having a circular cross-section, and, - The press surface is formed by the outer surfaces (12, 13) of the press roll. A laminating apparatus according to any one of features 1 to 7.

9. - Within the outer surface (12, 13), at least one outer segment is provided that is supported radially in a spring-elastic manner. The radially outer surface of the outer casing segment forms part of the press surface. The laminating apparatus according to feature 8.

10. - The press device has at least one press belt (20, 21), and, The press surface is formed by the surface of the press belt (20, 21). On this surface, the press belt contacts the endless web (3) under the action of pressing force. A laminating apparatus according to any one of features 1 to 7.

11. - The press belts (20, 21) have different spring stiffnesses along their longitudinal extension in the direction of the applied pressing force. The laminating apparatus according to feature 10.

12. - The press rolls (1, 2) contact the free sides of the press belts (20, 21) and press the press belts (20, 21) against the endless web (3) under the action of pressing force. A laminating apparatus according to any one of 8 or 9 and 10 or 11.

13. - The press rolls (1, 2) and / or the press belts (20, 21) are Moved and / or driven synchronously with respect to the endless web (3), A laminating apparatus according to any one of claims 8 or 9 and 10 to 12.

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